The production of the Ovaltine and Caotina drink mixes has long been controlled by ABB’s automation platform System 800xA. The need to increase pro-duction efficiency and flexibility led Wander to im-plement a Manufacturing Execution System (MES). With the introduction of ABB’s MES, part of the ABB Ability™ Manufacturing Operations Management (MOM) offering, Wander now also has complete hor-izontal and vertical integration — from the delivery of raw materials, to production, to finished prod-ucts, and from Enterprise Resource Planning (ERP) system to plant floor. The integration of the busi-ness system layer with the control system layer en-ables the synchronization of the production pro-cesses, transparency of all plant activities, as well as production improvement and optimization.

— C A S E S TU DY

In the mix: ABB’s Manufacturing Execution SolutionDrink maker Wander AG uses MES for increased efficiencies

Wander AG, maker of the globally popular Ovaltine and Caotina chocolate malt drinks, achieves increased efficiency and flexibility by introducing ABB’s Manufacturing Execution Solution (MES) in production processes.

Ovaltine and Caotina not only taste good — they have become an essential part of breakfast for many children all over the world. Developed more than 100 years ago, Ovaltine is a nourishing food beverage for children with its vitamin-rich properties from malt extract, milk and cocoa. It is recognized as an ideal combination of essential nutrients in a deli-cious, satisfying warm drink.

Wander’s plant in Neuenegg, Switzerland, one of its oldest Ovaltine production sites, faced the chal-lenge of increasing demand for capacity and flexibil-ity in a production facility whose structure has grown over many decades. Thus, Wander embarked on a project to modernize and streamline its pro-duction process to realize improved efficiency and flexibility.

The implementation of the MES system was part of a larger modernization project that also in-cluded changes in the physical building and higher level of automation in the logistics opera-tions (e.g., connecting the high rack warehouse to the production and automated guided vehicles). The major challenge for the parties involved was to maintain the production and logistics opera-tions without major interruptions. The constant changes through the individual projects required optimal coordination and fine-tuning. The high standards of product quality, hygiene and service delivery also had to be adhered to at all times.

New silos for raw and bulk products play a key role for optimal production processes. It is now possible to control material flows and to track production processes, thanks to an accurate and automatic data acquisition of the MES. Manual and paper-based pre-production steps, such as pre-weighing of raw material, are now also sup-ported by the system. Operators are guided through the weighing using ergonomic work-places and barcode scanners, thereby ensuring an accurate and efficient process at all times.

The new system now controls the work order picklists of the individual products. When the pro-duction order is downloaded from the ERP sys-tem, the MES system starts the batches and calls the necessary raw material, which is delivered via a driverless fork lift (AGV) from the high rack warehouse. Another part of the raw materials comes from the day silos. The required ingredi-ents in the dry mix are then combined, mixed dry or wet depending on the recipe, and then dried, granulated and bottled as a dry mixture. The sys-tem thus controls the overall formulation — from

the weighing of raw materials to the actual mix-ing process, including automatic dosing of all components supplied. With automation, error rates are reduced as the system instantly detects and interrupts the weighing or mixing process when any deviations are detected.

Other improvements that were realized with the new system include raw material handling. Before the project, whey powder and cocoa were deliv-ered in 25kg bags. Today, these ingredients are stored in silos with a daily capacity of 5,000kg, which are filled by big bags. The changed formats mean savings for Wander in terms of filling and raw materials input, as well as a significant reduc-tion of handling. A key functionality of the MES system is the seamless and complete traceability of all materials, equipment and persons involved in the production process. It is now possible to in-stantly view the genealogy of the products, all the way down to the mixing layers of powders in the silos.

Inventory is another area that has seen improve-ments. As material usage is booked back in to ERP as it is consumed, inventory is always up-to-date and correct. This enables timely material re-ordering and avoids corrective actions and un-planned downtime.

Convincing integrated solutionThe decision to go with ABB was based on a good experience with the existing 800xA process con-trol system, and ABB’s extensive know-how of fully integrated solutions, the availability of proven and tested applications and a good cost-performance ratio which results in early pay-back and sustainable ROI. “Not only were the

Benefits: Enabling productivity, quality and continuous improvement

functionality and technology of ABB’s ECS project solution convincing; they also showed experience and knowledge. It was a constructive and fruitful collaboration with ABB’s team,” said Steffen Grill, project manager of Wander AG.

Teamwork under time pressureHe continued, “The collaboration of Wander and ABB was very good and efficient. Because of the complexity of the project and time pressure, there were some predictable difficult stages. However, all were addressed professionally and effectively.” Additionally, production had to con-tinue during the restructuring. The well-synchro-nized teams of Wander AG and ABB met all chal-lenges. Together, we were able to develop constructive solutions,” he said.

CapabilitiesABB’s Enterprise Connectivity Solution as part of the MES offering provides the complete solution for seamless manufacturing and business pro-cesses integration, enabling true interoperability among all entities involved in the production pro-cess. The main MES capabilities deployed at Wan-der are:

Production order management:• Bi-directional integration of ERP to automati-

cally download orders from ERP to MES, and re-port back relevant information

• Comprehensive routing (workflow)• Overview of all production orders and statuses

Material management:• Track-and-trace provides complete traceability

of production orders, materials, batch, lots, equipment and personnel, leading to improved utilization and regulatory compliance.

• Weigh and dispense accuracy is improved by guiding operators with intuitive, user-friendly instructions on displays, supporting compli-ance and security procedures to ensure that correct material and quantity is dispensed by verification checks on materials, containers and scales through barcode technology.

• Wireless Barcode Scanning leads the operator through all relevant steps and captures material movement.

—“Not only were the functionality and technology of ABB’s ECS project solution convincing; they also showed experience and knowledge. It was a constructive and fruitful collaboration with ABB’s team,” Steffen Grill, project manager of Wander AG.

Warehouse management:• Container management is improved through

the Tote bins used for raw material; premix or finished material are managed including infor-mation regarding production order, lot, amount, fill date/time, cleaning, etc. which is available at all times.

• Silo levels and refilling are kept within defined ranges and material lots and mixing levels are continuously supervised to enable layered dis-pensing.

Other resultsManual efforts were significantly reduced in the following areas:• Raw material handling• Weighing and material preparation• Reporting back to ERP• Improvement of quality and reduction of errors

New production processes were made possible with raw material and bulk silos that track lots (layered dispensing).

In the area of supervision and control of manual activities, Wander has realized less errors and re-duced scrap. Material management is also im-proved as materials are booked back in ERP when it is consumed. This means inventory is always up-to-date and correct, enabling timely material ordering, corrective actions and less downtime.

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